Repairing the Trionic ECU by Saabben
Repairing the headlamp relay by John Carlyle-Clark

by SwingBopper
Replacing the blower motor brushes

Installing the Aquamist 1S water injection system by Mark Edgar

Tool for Compressing Drive Belt Tensioner by Duncan Edwards

Introduction

The exhaust flexible joint on my car had suffered damage due to excessive flexing
caused by worn engine mountings (naturally,
according to Murphy's law, this was the newest part of the exhaust system!)
and was blowing and getting worse. I decided that, since the rest of the system
was at least two years old (the length of time I had owned the car), this was
an opportunity to fit an upgraded exhaust system. I intend to add power upgrades
in the near future, and feel that a free-flow exhaust system, apart from adding
some top-end power and reducing turbo lag, will reduce stress on a tuned engine.
I considered three systems: the stainless steel system from Abbott Racing, an
aluminised steel 2.5" system from Jetex and the 3" aluminised steel
"JT" system from Speedparts in Sweden.

Decisions, decisions...

Here was my decision-making process. Naturally, like choice of tyres,
this was based on my own priorities, which may be very different from those
of others. My criteria were:

Performance improvement
The exhaust system must provide a worthwhile performance improvement, though
not necessarily on its own. I was planning ahead to other performance upgrades,
such as reprogrammed engine management, and intended that the new exhaust
system should help relieve stress from a tuned engine. I was hoping, however,
that a free-flow exhaust alone might reduce turbo lag and provide some small
power increase at high RPM.

Discreet appearance
I was not in the slightest bit interested in having a tailpipe that marked
me as a "boy racer". The less conspicuous, the better. My ideal
system would have looked identical to the standard 9000 Aero exhaust system.

Quiet
Although I wanted performance, the last thing I wanted was to turn my executive
car into a Formula-1 style "racing machine". Sometimes, though not
often, I have to drive hundreds of miles at a time. The Aero seats are the
most comfortable and supportive fitted to any 9000 - I didn't want to develop
a headache through exhaust noise (honestly, I have been told by one Saab owner
that the exhaust system on his 900 convertible gave his wife a headache!).
Again, I didn't want to sound like a "boy racer" around town.

So on to the systems I considered...

Finally, the verdict...

While the JT system is louder than the standard exhaust system, is is
not obtrusively so, at least to my own ear. In comparison to "boy-racer"
cars with loud stainless steel exhausts, my car simply sounds "powerful,
but understated". As far as performance is concerned, turbo lag (more of
a problem on the manual Aero, with its larger turbo) is much reduced, making
the car more responsive. Top-end power, subjectively, was also increased, but
I didn't put the car on a dynamometer, so I can't quantify the improvement.
Maptun estimate an extra 10hp. Fuel economy is at least as good, and possibly
slightly better. It is difficult to tell as I now drive the car a bit harder
to make use of the new-found responsiveness.

Time required

Around 3-4 hours.

Tools required

13mm spanner.

14mm spanner.

1/4" T-bar and 13mm socket.

Copper grease (copper anti-seize compound).

Dismantling lubricant, such as "Plus-Gas" or "Liquid Wrench".

Have a hacksaw ready, just in case.

Additional parts required

6 rubber exhaust mountings. Original Saab mountings were the best I could
find.
Note that I had to fabricate lengthened mountings for the cat (see below).